Design And Fabrication Of Beam Engine Powered

Receprocating Saw

TERNA ENGINEERING COLLEGE ,

NERUL,NAVI MUMBAI
UNIVERSITY OF MUMBAI 2021-2022

SE MECH SEM III ( Mechanical Engineering )

MINI PROJECT 2021-22
BY GROUP 7
HARSHVARDHAN BALLAL ( TU5S2122010 )
MAHESH PATIL ( TU5S2122051 )
GITESH MHASKE ( TU5S2122057 )
ROHIT KAMBLE ( TU5S2122070 )

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 CERTIFICATE
This is to certify that the mini project entitled ” Design And Fabrication Of Beam
Engine Powered Receprocating Saw ” is a Bonafede record of the Mini Project
work done by HARSHVARDHAN BALLAL ( TU5S2122010 ) , MAHESH
PATIL ( TU5S2122051 ) , GITESH MHASKE ( TU5S2122057 ) ,

ROHIT KAMBLE ( TU5S2122070 ) , in the year 2021-22 Department of

Mechanical Engineering submitted to the University of Mumbai in partial
fulfilment of the requirement for the award of the degree of III Semester “Bachelor
of Engineering” in “Mechanical Engineering”.

PROF . VAISHNAVKUMAR WAGH

GUIDE

DR. C.M. CHOUDHARI DR. L.K. RAGHA

Head of Department Head of Department Principal

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 DECLARATION

Declaration I declare that this written submission represents my ideas in my own

words and where others; ideas or words have been included, I have adequately
cited and referenced the original sources. I also declare that I have adhered to all
principles of academic honesty and integrity and have not misrepresented or
fabricated or falsified any idea/data/fact/source in my submission. I understand that
any violation the above will be cause for disciplinary action by the Institute and
can also evoke penal action from the sources which have thus not been properly
cited or from whom proper permission has not been taken when needed. Of

HARSHVARDHAN BALLAL ( TU5S2122010)

GITESH MHASKE (TU5S2122057 )

MAHESH PATIL ( TU5S2122051 )

ROHIT KAMBLE ( TU5S2122070 )

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 MINI PROJECT REPORT APPROVAL

This mini project report entitled developing by

HARSHVARDHAN BALLA ( TU5S2122010 ) , MAHESH PATIL (

TU5S2122051 ), GITESH MHASKE (TU5S2122057 ) , ROHIT KAMBLE (
TU5S2122070 ) is approved for the S.E. III semester degree of Bachelor of
Engineering in Mechanical Engineering.

Examiners:

1.

2.

Date:

Place:

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 INDEX
Table of Contents

Sr CONTENT Page
no. no
1 ABSTRACT 06
2 INTRODUCTION 07
3 DEVLOPMENT OF IDEA , DISCUSSION AND 08
SIGNIFICANCE
4 STAGES IN NEW PRODUCT DEVLOPMENT 09
5 METHODOLOGY 10
6 SYSTEM DESIGN AND COMPONENT 20
7 WORKING PRINCIPLE 23
8 DIGRAM 27
9 BILL OF MATERIAL 28
10 ADVANTAGES 29
11 LIMITATION 30
12 APPLICATION 31
13 CONCLUSION 32
14 REFRENCE 33

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 ABSTRACT

In this project, the output of a Beam Engine is used to drive a reciprocating saw to
cut timber. Here, instead of the rotating fly wheel, it is intended to have a rotating
reciprocating saw. This rotating reciprocating saw is used to cut timber.
Reciprocating saws driven with electric power are a common feature. But in places
where electricity is scarce, or absent, it is difficult to operate these equipments. But
since the Beam Engine powered saw runs on fuel, it can be operated even in places
where electricity is totally absent. A beam engine is a design of stationary steam
engine [1]. A stationary engine is an engine whose framework does not move [2].
Usually, a stationary engine is used not to propel a vehicle but to drive a piece of
immobile equipment such as a pump or power tools [4]. In a beam engine, the piston
is mounted vertically, and the piston rod does not connect directly to the connecting
rod, but instead to a rocker or beam above both the piston and flywheel. The beam
is pivoted in the middle, with the cylinder on one side and the flywheel, which
incorporates the crank, on the other. The connecting rod connects to the opposite end
of the beam to the piston rod, and then to the flywheel

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 INTRODUCTION
A beam engine is a type of steam engine where a pivoted overhead beam is used to
apply the force from a vertical piston to a vertical connecting rod. This
configuration, with the engine directly driving a pump, was first used by Thomas
Newcomen around 1705 to remove water from mines in Cornwall . The efficiency
of the engines was improved by engineers including James Watt who added a
separate condenser, Jonathan Hornblower and Arthur Woolf who compounded the
cylinders, and William McNaught (Glasgow) who devised a method of
compounding an existing engine. Beam engines were first used to pump water out
of mines or into canals, but could be used to pump water to supplement the flow
for a waterwheel powering a mill .
The rotative beam engine is a later design of beam engine where the connecting
rod drives a flywheel , by means of a crank (or, historically, by means of a sun and
planet gear ). These beam engines could be used to directly power the line-shafting
in a mill . They also could be used to power steam ships .

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 DEVELOPMENT OF IDEA, DISCUSSION AND
SIGNIFICANCE
As mentioned earlier the motivation for this project being the course ME 637, the
course required each student to submit a project using the Pro-E modeling tool and
the instructor emphasized that the project should be creative and something new.
This made me think about something new and finally I arrived at the Beam Engine
idea. The word “power tools” caught my attention and I just started to think why
not I use a beam engine to drive a circular saw to cut timber. While electric
powered saws are a common feature as also diesel and gasoline powered saws, a
saw that works on the principle of a beam engine is something that I thought of.
This saw, which can run either on diesel or gasoline, can be used in places where
electricity is sparse or absent.

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 STAGES IN NEW PRODUCT DEVELOPMENT

1. Idea generation
2. Idea screening
3. Concept development & testing
4. Market strategy development
5. Business Analysis
6. Test Marketing
7. Commercialization

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 METHODOLOGY

DESIGN OF MACHINE:-
In our attempt to design a special purpose machine we have adopted a very a very careful
approach, the total design work has been divided into two parts mainly;
• System design
• Mechanical design
System design mainly concerns with the various physical constraints and ergonomics, space
requirements, arrangement of various components on the main frame of machine no of controls
position of these controls ease of maintenance scope of further improvement; height of m/c from
ground etc.

In Mechanical design the components are categoriesed in two parts.

• Design parts
• Parts to be purchased.

For design parts detail design is done and dimensions thus obtained are compared to next highest
dimension which are readily available in market this simplifies the assembly as well as post
production servicing work.The various tolerances on work pieces are specified in the
manufacturing drawings. The process charts are prepared & passed on to the manufacturing stage
.The parts are to be purchased directly are specified &selected from standard catalogues.
Methodology can properly refer to the theoretical analysis of the methods appropriate to a field
of study or to the body of methods and principles particular to a branch of knowledge. In this
chapter, it talks about the methods use to gather information in order to finish the research. It was
involve the process flow of every step in archive the objective of this project. There are many
methods use in this project such as internet references, interviewing lecturers and technicians and
the most important is group discussion.

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11
MATERIAL SELECTION & METHODOLOGY

1.1 Material Selection

The proper selection of material for the different part of a machine is the main objective. In
the fabrication of machine. For a design engineer it is must that he be familiar with the effect,
which the manufacturing process and heat treatment have on the properties of materials. The
Choice of material for engineering purposes depends upon the following factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials
4. Physical and chemical properties of material.
5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability of the
material to resist mechanical forces and load. We shall now discuss these properties as
follows:
A. Strength B. Elasticity
C. Stress D. Plasticity
E. Stress F. Ductility
G. Brittleness H. Malleability
I. Toughness J. Resilience

When a part is subjected to a constant stress at high temperature for long period Of time, it
will undergo a slow and permanent deformation called creep. This property is considered in
designing internal combustion engines, boilers and turbines.

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HARDNESS

It is a very important property of the metals and has a wide verity of meanings. It embraces
many different properties such as resistance to wear scratching, deformation and mach
inability etc. It also means the ability of the metal to cut another metal.

The hardness is usually expressed in numbers, which are dependent on the method of making
the test. The hardness of a metal may be determined by the following test.
1. Brinell hardness test
2. Rockwell hardness test
3. Vickers hardness (also called diamond pyramid) test and
4. Share scaler o scope.

In engineering practice, the machine parts are subjected to various forces, which may be due
to either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Fictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that are set up
during operation. The material selected should with stand it. Another criterion for selection
of metal depends upon the type of load because a machine part resist load more easily than a
live load and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.

1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs
Methodology of Design & Analysis

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*Methodology of Design & Analysis:

A parameter study is done to evaluate the most crucial parameters for FE analysis of axial
ball bearings. The parameters that are evaluated are mesh density, contact stiffness,
osculation, load level, geometrical nonlinearity and material nonlinearity. The studies are
performed by means of the FE software Ansys. The accuracy of finite element analysis
depends on different parameters such as element type, boundary condition and how the loads
are applied etc. Therefore the FE model is nothing else but an approximate realization of the
reality. The parameter study can be done by physical tests. However it will increase the cost,
time and resources consumed and therefore FE analysis is more suitable choice, at least for
parameter evaluation.

*Theoretical aspects of the work :

In this study the finite element method is adopted using Pro Engineer and Ansys as a
commercial CAD and FE program. The following chapter contains some fundamentals of the
applied theories provided that the reader has an initial knowledge of basic structural
mechanics, machine components, and fundamentals of the finite element method.

*Finite element method :

Finite element method (FEM) is a method for approximate solutions of partial differential
equations. The domain of interest is divided into finite elements on which the solution is
approximated by piecewise-polynomials. The finer the partition (Mesh) is, the more accurate
the solution.

*Nonlinear Analysis :
Nonlinear analysis is used when a structure behaves nonlinear when loaded i.e. the
deformation and the stress state does not have a linear relation to the applied load. The three
main sources to nonlinear behaviors are: contact, geometric nonlinearities and material
nonlinearities. In order to manage such calculations with a linear process the Newton
Raphson method can be used.

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Newton-Raphson method

Newton-Raphson is an iterative method for finding solution to nonlinear equations and equation
systems . In FE calculations the method is used for non-linear problems and the relations
between force and displacement is shown in Figure 2.1 for one degree of freedom. The
procedure for Newton-Raphson method is as follows: The load is applied and the displacements
are calculated. From the displacements new conditions are calculated and the displacements are
recalculated. This procedure is repeated until the solution is converged i.e. reach a certain value
or level.

The iterative procedure is as follows:

Material nonlinearities

A nonlinear stress-strain relationship results in a nonlinear behavior. Plasticity is a nonlinear

stress-strain relationship as shown in Figure 2.4. Definition of Plasticity according Ansys (2007)
is: “When a ductile material experiences stresses beyond the elastic limit, it will yield, acquiring
large permanent deformations.”

Fig.6 Relationship Between Stress & Strain

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Ansys

Ansys is a commercial, general purpose FE software which has been on the market since 1971. It
can be used in several applications for example to study the thermal heat flow, fluid flow,
magnetic fields, acoustics/vibrations and last but not least structural mechanical problems.

Contact in Ansys

A handful of ways to handle contact are available in Ansys. However, the one described here is
penalty based contact since it provides short calculation times and therefore is used.

Penalty based contact

When a penalty-based contact is used, Ansys adds a spring coefficient (k factor) when two
surfaces come in contact with each other, in order to prevent penetration and to transfer load.
(Figure 2.7) However penetration will occur in order to transfer force, which is not the case in
reality. Therefore the penalty-based methods are sensitive to the choice of the spring coefficient.
The spring coefficient Ansys uses during calculations is the product between the “normal
stiffness factor” specified by the user and a reference factor calculated by the program. An
additional aspect (apart from the accuracy) to consider when selecting the “normal stiffness
factor” is the convergence behaviour. A stiffer contact will result in more calculation iterations,
since bouncing might occur.

Fig.7 Contact Stiffness

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Asymmetric behaviour

A contact condition can be either symmetric or asymmetric. When the contact condition is
symmetric none of the surfaces can penetrate each other, while when the contact is specified as
being asymmetric only one of the surfaces is prevented from penetrating the other i.e. the contact
surface can not penetrate the target surface but the opposite is possible. Figure 2.8 illustrates the
importance of selecting the correct contact pair.

Fig.8 Asymmetric behaviour

Bilinear stress-strain curve

In context of the license version used, Ansys tender a bilinear approximation of the stress-strain
relationship as in figure 2.9. The bilinear stress-strain curve requires two input values, yield
strength and tangent modulus. The yield strength is the value when plastics straining occurs and
the tangent modulus is the slope of the stress-strain curve after yielding.

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Fig.10 Relationship Between Stress & strain, Bilinear curve in Red & True Material Relation in
blue

Meshing controls

Ansys offers several tools to control the meshing procedure. The mesh densities of the whole
model can be controlled by global settings for relevance centre in three steps: coarse, medium or
fine.

Method

Method is a meshing control that provides the possibility to select different elements shapes. The
different elements that are available are: tetrahedron or quadrilateral. Tetrahedron elements are
triangular pyramid like elements with 10 or 4 nodes and quadrilateral elements are cube elements
with 20 or 8 nodes.

Mechanical Projects : Learnmech.com

BEAM ENGINE POWERED HACKSAW

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Sizing

Sizing is a meshing control that provides the possibility to mesh with different mesh densities at
selected regions. By meshing fine in the area of interest and using coarse mesh in the remaining
parts one is able to reduce CPU time and memory usage. There are a couple of ways to select the
region of a sizing control available in Ansys. The region can be a surface. This will produce a
fine mesh (or actually a mesh with the size specified) on the surface only. The region can also be
an entire body which will produce a fine mesh all over the body. If a contact region is to be
analysed, Ansys offers the possibility to specify the mesh size in the contact region. And to
capture a local behaviour it is possible to specify a so called sphere of influence which makes it
possible to set the element size (mesh size) within the volume of a sphere. The sphere of
influence can be used to enclose both faces and bodies.

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 SYSTEM DESIGN & COMPONENT

In our attempt to design a special purpose machine we have adopted a very a very careful
approach, the total design work has been divided into two parts mainly;

System design

Mechanical design

System design mainly concerns with the various physical constraints and ergonomics , space
requirements, arrangement of various components on the main frame of machine no of
controls position of these controls ease of maintenance scope of further improvement ;
weight of m/c from ground etc.

In Mechanical design the component in two categories.

Design parts

Parts to be purchased.

For design parts detail design is done and dimensions thus obtained are compared to next
highest dimension which are readily available in market this simplifies the assembly as well
as post production servicing work.

The various tolerance on work are specified in the manufacturing drawings the process
charts are prepared & passed on to the manufacturing stage .The parts are to be purchased
directly are specified &selected from standard catalogues.

*System Design
In system design we mainly concentrate on the following parameter

1.1 System selection based on physical constraints :

While selecting any m/c it must be checked whether it is going to be used in large scale or small
scale industry in our care it is to be used in small scale industry so space is a major constrain
.The system is to be very compact it can be adjusted to corner of a room. The mechanical design
has direct norms with the system design hence the foremost job is to control the physical
parameters so that the distinction obtained after mechanical design can be well fitted into that.

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1.2 Arrangement of various component :
Keeping into view the space restriction the components should be laid such that their easy
removal or servicing is possible moreover every component should be easily seen & none should
be hidden everypossible space is utilized in component arrangement.
1.3 Components of system :
As already stated system should be compact enough so that it can be accommodated at a corner
of a room. All the moving parts should be well closed & compact A compact system gives a
better look & structure.

1.4 Man –m/c Interaction :

The friendliness of m/c with the operation is an important criterion of design. It is application of
anatomical Following are some e.g. of this section.

1.5 Chances of failure:

The losses incurred by owner in case of failure of a component are important criteria of design. Factor of
safety while doing the mechanical design is kept high so that there are less chances of failure there over
periodic maintenance is required to keep the m/c trouble free.

1.6 Servicing facility:

The layout of components should be such that easy servicing is possible especially those
components which required frequent servicing can be easily disassembled.

1.7 Weight of machine :

The total weight of m/c depends upon the selection of material components as well as dimension
of components. A higher weighted m/c is difficult for transportation & in case of major break
down it becomes difficult to repair.

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Mechanical Design :
Mechanical design phase is very important from the view of designer as whole success of the
project depends on the correct deign analysis of the problem. Many preliminary alternatives are
eliminated during this phase. Designer should have adequate knowledge above physical
properties of material, loads stresses, deformation, and failure. Theories and wear analysis, He
should identify the external and internal forces acting on the machine parts
These forces may be classified as;
a) Dead weight forces
b) Friction forces
c) Inertia forces
d) Centrifugal forces
e) Forces generated during power transmission etc

Designer should estimate these forces very accurately by using design equations .If he does not
have sufficient information to estimate them he should make certain practical assumptions based
on similar conditions which will almost satisfy the functional needs. Assumptions must always
be on the safer side.

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 WORKING PRINCIPLE

When the piston in the cylinder reciprocates, it imparts an oscillating motion to the
rocker arms, as shown in figure 1 on page 2. This oscillating motion of the rocker
arm is converted into rotary motion by the crankshaft. The crankshaft, which is
connected to the circular saw, makes the circular saw rotate. This rotary action of
the circular wood saw is used to saw timber or wood blocks. There is a small table
attachment for supporting the wooden block. The wooden block is placed on the
table and pushed towards the rotating wood saw, which results in the sawing
action. The main advantage of this machine is that it can be used in places where
electricity is not economical or in places where electricity is absent.

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24
EXPERIMENTAL SETUP
A beam engine mechanism is one where we use an overhead beam to create motion. Here we use
a beam engine motion based assembly in order to achieve hack saw cutting motion using a
circular cutting disc. Our system uses a motorized disc to drive a connector which is in turn
connected to an overhead beam. The overhead bean has a connecting rod in turn connected to a
mini hacksaw blade. When the motorized disc below is turned on the connecting arm starts
reciprocating the overhead beam. This beam now heals achieve a back and forth cutting motion
as required by the hacksaw blade.

We construct a small bed in order to rest the work piece to achieve desired cutting. Thus we
study thedesign and fabrication of mini hacksaw using beam engine mechanism.

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WORKING OF RECIPROCATING HACKSAW ;-
The objective of this work is to automate the conventional power hacksaw machine in order to
achieve high productivity of work-pieces than the power hacksaw machine using pneumatic
power. Pneumatic is a huge topic of science and engineering dealing with the mechanical
properties of air. In our project we take this pneumatic and a hacksaw for cutting purpose, The
pneumatic reciprocating high- speed hacksaw machine has an advantage of working in high
pressure , the hacksaw used in this is reciprocate such that required shape can be cutted
according to the requirement. The hacksaw is the metal cutting machine tool designed to cut
metal by applying pneumatic pressure. Hacksaws are used to cut thin and soft metals the
operation of the unit is simplified to a few simple operations involving a cylinder block and
piston arrangement. There are numerous systems in hacksaw machine. The hacksaw is the metal
cutting machine tool designed to cut metal by applying pneumatic pressure. The machine
exclusively intended for mass production and they represent fasten and more efficient way to cut
a metal. Hacksaws are used to cut thin and soft metals the operation of the unit is simplified to a
few simple operations involving a cylinder block and piston arrangement. There are numerous
systems in hacksaw machine .The main function of pneumatic hacksaw is to cut thin and soft
metals by pneumatic power.

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DIGRAM

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Bill of material

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 ADVANTAGES

1. The cutting speed can be varied according to our needs by adjusting the timer.
2. It is portable.
3. It does not have any prime mover like electric motor.
4. Simple in construction than mechanical hacksaw.
5. It is compact one. 6. Less maintenance.

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 LIMITATION

1. Only smaller size and soft metal can be cut.

2. It is costlier than the mechanical hacksaw because of compressor unit.
3. Less efficiency when compressor to mechanical device
4. Leakage of air affects the working of the unit.

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 APPLICATION

1. It is used in small scale industries and in large scale industries.

2. It useful when materials need to be cut in hazardous areas such as oil & gas
refineries, chemical factories or oil rigs as well as dusty and wet environments
where electric tools are not effective.
3. It is valuable tools in production environments such as pallet repair, shipbuilding
or fiberglass workshops, because they will last longer than electric tools.

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 CONCLUSIONS

This being a creative project, there are no particular instances of this type of
machine being available in the commercial market. But the aim of this project is to
show that this type of machine too is an option for wood working industry in
remote places in the absence of electricity. Further improvements include using
reduction gears, to vary the speed of the circular saw, having an adjustable bed
with slots for adjusting the table length, so that even large sizes of timber can be
sawed by varying the distance of the table and the size of the circular saw.

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 REFERENCES

1. THEORY OF MACHINES-R.S.Khurmi;S.S Ratan.

2. Design Of Machine Elements-V.B.

Bhandari,Shingley,R.L. Norton

3. Mechanics of solids

4. Wikipedia https://en. wikipedia.org/wiki/Main Page

5. Scienecedirect.com searched on 2-1-2018.

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